Hats exhibiting brim imagery, detachable brim imagery, and method of making and displaying the same

ABSTRACT

Hats having images, including those with images displayed on the upper or lower surface of the brim. Exemplary hats include baseball hats with brims adapted to affix at least one image to the brim&#39;s lower surface, wherein said at least one image is detachable. Also described are displays, including kits and packages, comprising at least one detachable image adapted to be affixed to the upper surface or lower surface of a hat brim.

FIELD

The present disclosure relates to the preparation and use of a hat having brim imagery, e.g., a printed image displayed on the underside of the hat's brim, which may optionally be removable.

BACKGROUND

Various methods for applying an image to clothing and fabrics are known, including the use of silk-screen printing and sublimation printing. Baseball hats, for example, may be decorated by providing a logo, e.g., on the front panel. This may be accomplished by printing a logo directly on the hat by a process including digital heat transfer printing, direct screen printing, etc.

However, the area on or under the brim of the hat is typically underutilized, exhibiting a blank space without imagery. Accordingly, there remains a need to provide baseball hats exhibiting, including imagery on the lower surface of the brim. There also remains a need to provide suitable and cost-effective means for generating such images, and even make such images detachable and/or replaceable.

SUMMARY

Described herein are hats, including baseball hats, comprising a brim and at least one image. In certain embodiments, the brim has an upper surface and a lower surface. In certain embodiments, the brim is adapted to affix at least at least one image. In certain embodiments, the lower surface of the brim is adapted to affix the at least one image. In certain embodiments, the at least one image is detachable and/or replaceable

Also described herein are displays comprising a hat having a brim, and instructions for obtaining at least one image adapted to be affixed to the brim, and/or instructions for affixing at least image to the brim. In certain embodiments, the display comprises a kit or packaging, wherein said kit or packaging comprises the hat, the instructions, and, optionally, the at least one image. In certain embodiments, the display comprises a store-type display rack, wherein said rack contains the hat, the instructions, and, optionally, the at least one image.

Further described is a method comprising selecting a hat having a brim, said brim having an upper surface and a lower surface, and affixing at least one image to the brim, wherein the at least one image comprises printed material disposed on a substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary baseball hat.

FIG. 2 is a bottom view of an exemplary baseball cap having an image affixed to the lower surface of the brim.

FIG. 3 is a view of an an exemplary perforated image.

DETAILED DESCRIPTION

Described herein are hats and methods of making and using the same. Exemplary hats include the baseball caps such as cap 100 set forth in FIG. 1, which comprises brim 106 and cap portion 108. The hat may also comprise front panel 102. Brim 106 includes upper surface 104 and lower surface 206. Cap portion 108 typically covers the top of the wearer's head. Front panel 102 may be used to display text and/or imagery. The brim may also be referred to as a “bill.” In certain embodiments, the hats described herein may comprise any type of hat having a brim. For example, the hat may be a “visor” that comprises a brim but lacks a cap portion

FIG. 2 exemplifies the underside of hat 100, which includes brim lower surface 206 and image 202. In certain embodiments, lower surface 206 is adapted to affix image 202. Image 202 may be prepared by any method known to those of skill in the art, including stitching, image transfer, sublimation printing, or screen printing. In certain embodiments, image 202 is detachable from the brim. For example, in certain embodiments image underside 204 (e.g., the substrate) of image 202 may comprise a material that is capable of “clinging” or “adhering” to lower surface 206, such that image 202 can be peeled away and optionally replaced with another image. In certain embodiments, lower surface 206 may comprise a non-fabric surface (e.g., smooth polymeric material) that aids in the clinging and/or adhering of image 202.

Additionally, hat 100 may further comprise written information related to the identity of image 202. For example, as shown in FIG. 2, tag 208 may be implemented to provide written information—independent and away from image 202 itself—related to the identify of image 202. In this example, tag 208 contains written information related to the golf hole imagery of image 202, including the hole #, par, and yardage. In another embodiment, image 202 could comprise imagery of the famous Banzai Pipeline surf break in Haleiwa, Hi., wherein tag 208 contains written information identifying the wave as “Pipeline” and/or other information including the name of the beach (“Ehukai”), zip code (“96712”), or longitude/latitude coordinates. Other exemplary images may include, for example, professional sports stadiums and sports venues, professional sports players, landscapes, etc. In certain embodiments, front panel 102 can be used to provide the logo of a sports team (e.g., San Francisco Giants), while image 202 provides imagery of a player on the team (e.g., Buster Posey) or the stadium (e.g., AT&T Park).

In a further embodiment, hat 100 and image 202 may comprise multiple images. For example, in certain embodiments, lower surface 206 may comprise a primary image. Thus, in certain embodiments, application of image 202 to hat 100 will “replace” the primary image, as image 202 will “cover” the primary imagery that comprises lower surface 206.

Exemplary brims may comprise a rigid or semi-rigid insert (e.g., cardboard or plastic such as polyvinyl chloride) covered with a fabric material (e.g., cotton and/or polyester). The fabric material is typically secured to the upper and lower surfaces of the brim via stitching. Similarly, the front panel of the hat may comprise a fabric material. Thus, common printing methods typically involve the transfer of an image directly to the fabric of the hat, such as the front panel. However, when images are printed/transferred directly to the fabric of the hat, the method typically comprises the use of high temperatures (e.g., greater than 250° F.), which may result in deformation of the image and/or portion of the hat to which the image is applied (e.g., the brim insert). For example, application of an image directly to the fabric surface of a brim at high temperature may first require the flattening of the brim before the image can be transferred, which subsequently requires reforming the curvature of the brim/brim insert through a time-consuming cooling and heating process. Moreover, transferring the image directly to a surface of the hat results in a permanent image that cannot be detached from the hat.

In certain embodiments, Applicant has surprisingly discovered that images can be prepared separately and subsequently attached to the hat—such as the lower surface of the brim—wherein concerns related to the direct application of an image to a surface of the hat are alleviated. In certain embodiments, this accomplished by separately preparing an image that comprises imagery disposed on a substrate. The prepared image can then be subsequently affixed to the hat (e.g., lower surface of brim) by any suitable means, such as stitching, static cling technology, adhesion, or a fastener-type system. By implementing the use of imagery disposed on a substrate, the image may subsequently be detached and, optionally, replaced with another image without compromising the structural integrity of the original hat structure. Contrariwise, direct transfer of imagery to the fabric of the hat's brim would not allow for the detachment/removal of the image without damaging the original structure of the hat.

As noted above, with reference to FIG. 2, in certain embodiments image 202 comprises imagery disposed on a substrate. Image 202 can then be affixed to lower surface 206 by any suitable means. When image 202 comprises the use of static-cling and/or adhesion technology, lower surface 206 may comprise a polymeric material that is not fabric. For example, in certain embodiments brim 106 may be constructed of a polymeric brim insert, wherein only the upper surface of brim 106 is covered with fabric—leaving the lower surface of the polymeric brim insert exposed to effect direct contact with image underside 204. In certain embodiments, the lower surface of the polymeric brim insert comprises a smooth finish (e.g., non-porous polymeric material) that is adapted to affix an image through the use of adhesion or static cling technology (e.g., a flexible vinyl cling, polyester cling, or vinyl with low-tack backing). In certain embodiments, the imagery is disposed on the substrate using any methods known to those of skill in the art. In certain embodiments, the image comprises stitched and/or printed imagery disposed on a fabric substrate. In certain embodiments, the imagery comprises printed material disposed on a polymeric substrate such as vinyl, polyester, or polyvinyl chloride.

A brim or image is generally considered “adapted to affix” when the brim is capable of receiving the image, and the image is capable being affixed to the brim. That is, the brim or image may be considered “adapted to affix” when one is capable of mating to the other when implementing a chosen system. For example, a brim having a lower surface that comprises a fabric material may not be adapted to affix an image comprising a vinyl static-cling substrate; on the other hand, a brim having a lower surface that comprises a fabric material may be adapted to affix an image comprising the use of stitching or a restickable adhesive when the image substrate comprises a fabric substrate or a polymeric substrate, respectively.

In certain embodiments, the imagery is transferred to a substrate to provide the image, which may be subsequently affixed to a finished or fully assembled baseball hat. In certain embodiments, the image may be affixed to the brim of the hat in any condition, irrespective of whether the brim is in a generally flat or curved shape during the process. In certain embodiments, the imagery is printed on the substrate using known processes. In certain embodiments, the image is printed using heat. In certain embodiments, the process is sublimation printing. Any sublimation printing process known in the art may be used. For example, imagery may be printed onto a transfer material, and then the image may be transferred on to the substrate through the use of heat. The transfer for use in the printing process may be of any design, and the transfer material may be any used in the printing industry. In certain embodiments, the sublimation printing comprises printing an image onto a transfer material using sublimation inks, and positioning the transfer material on the substrate and applying heat and pressure to transfer the sublimation inks to the substrate. In certain embodiments, primary imagery may be applied directly to the hat by, e.g., sublimation. In certain embodiments, subliming the primary imagery directly to the hat comprises the transfer of sublimation inks from a transfer material. In certain embodiments, the sublimation inks further contain polymeric-type resins, which may provide support/stability to the transferred image.

As described herein, in certain embodiments the hat may adapted to affix at least one image, wherein the at least one image is provided separately (i.e., not affixed) from the hat. Accordingly, in certain embodiments that at least one image should be customizable to the hat of the wearer. For example, as shown in FIG. 3, image 202 may be adapted to allow the user to customize the size of the image to fit a particular size of hat/brim. Exemparly images may comprise microperforations (e.g., small, medium, and large perforated outlines) that allow the wearer to “size” the image to fit their lower surface of their hat's brim.

Accordingly, in certain embodiments is described a hat comprising a brim having an upper surface and a lower surface, wherein the brim is adapted to affix at least one image. In certain embodiments, the lower surface is adapted to affix the at least one image. In certain embodiments, the at least one image is detachable. In certain embodiments, the at least one image comprises imagery and a substrate. In certain embodiments, the at least one image comprises imagery disposed on a substrate. In certain embodiments, the at least one image comprises screen-printed imagery. In certain embodiments, the at least one image comprises inkjet-printed imagery. In certain embodiments, the at least one image comprises a sublimed imagery. In certain embodiments, the imagery comprises one or more inks. Exemplary images may include, or example, professional sports stadiums and sports venues, professional sports players, landscapes, etc.

In certain embodiments, the imagery is derived from at least one digital image capture, such as a digital image originally captured from a digital camera or digital rendering. In certain embodiments, the imagery has a resolution of at least 300 dots per inch. In certain embodiments, the imagery has a resolution of at least 360 dots per inch. In certain embodiments, the imagery has a resolution of at least 600 dots per inch. In certain embodiments, the imagery has a resolution of at least 720 dots per inch.

In certain embodiments, the substrate comprises at least one fabric-type material. In certain embodiments, the substrate comprises at least one polymeric-type material. In certain embodiments, the substrate comprises a cotton material. In certain embodiments, the substrate comprises a polyester material. In certain embodiments, the substrate comprises a vinyl material. In certain embodiments, the vinyl material comprises polyvinyl chloride.

In certain embodiments, the brim is adapted to affix the at least one image via a system that comprises the use of stitching. In certain embodiments, the brim is adapted to affix the at least one image via a system that comprises the use of static cling. In certain embodiments, the brim is adapted to affix the at least one image via a system that comprises the use of an adhesive. Exemplary adhesives include, but are not limited to, a restickable adhesive. Restickable adhesives may include “wet” or “dry” adhesives known to those of skill in the art, such as synthetic “setae” designed after the feet of a gecko. In certain embodiments, the restickable adhesive comprises a low-tack adhesive such as a low-tack acrylic adhesive. In certain embodiments, the imagery may be printed on a substrate comprising a low-tack adhesive backing, such as Low-Tack Vinyl produced by LexJet® of Sarasota, Fla. Exemplary printers may include small- and large-format inkjet printers such as those produced by Roland DGA® of Irvine, Calif. In certain embodiments, the brim is adapted to affix the at least one image via a system that comprises the use of fastener-type system. In certain embodiments, the fastener system comprises Velcro® marketed by Velcro USA Inc. of Manchester, N.H. In certain embodiments, the fastener system comprises Dual Lock™ technology marketed by The 3M Company of Minneapolis, Minn.

In certain embodiments, the at least one image is adapated to cover at least 50% of the area comprising the upper surface or the lower surface of the brim. In certain embodiments, the at least one image is adapated to cover at least 50% of the area that comprises the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover at least 75% of the area comprising the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover about 50% to about 100% of the area comprising the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover about 70% to about 100% of the area comprising the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover about 75% to about 100% of the area comprising the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover about 85% to about 100% of the area comprising the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover about 90% to about 100% of the area comprising the upper surface or the lower surface. In certain embodiments, the at least one image is adapted to cover about 95% to about 100% of the area comprising the upper surface or the lower surface. In certain embodiments, the coverage areas is the coverage are of the lower surface of the brim.

As previously described herein, in certain embodiments the hat is adapted to affix at least one image. However, the hat itself may simply be “adapted” by a manufacturer to “affix” the image, wherein the hat itself is produced and marketed without the image affixed to said hat. Nevertheless, in certain embodiments, it may be desirable to manufacture and market the hat with at least one image already affixed with the hat, or packaged with the hat to be affixed to the hat at a later time by the user. Thus, in certain embodiments, the hat further comprises the at least one image. In certain embodiments, a hat adapted to affix at least one image may be acquired by a user, allowing the user to prepare their own digital imagery (e.g., inkjet-printed image on vinyl) for attachment to the hat.

Also previously described herein are hats that further comprise written information relating to the identity of the image. For example, it may be desirable to provide written information on—or attached to—the hat, wherein the written information relates to, e.g., the name or geographic location of the image. For example, an image depicting the 9^(th) hole green of the Turtle Bay Resort may provide such identifying information on a tag affixed to the hat. In certain embodiments, the written information is not contained within the at least one image, and is thus separate from the area (e.g., lower surface area) covered by the image.

As discussed above, in certain embodiments the hat and the image may be manufactured and marketed separately. Accordingly, in certain embodiments is described a a display comprising: a hat having a brim, said brim having an upper surface and a lower surface, wherein said brim is adapted to affix at least one image; and instructions for obtaining and/or affixing the at least one image to the brim. In certain embodiments, the display further comprises the at least one image.

Exemplary displays include a kit or package in which the hat is sold, or an in-store display rack in which the hat is displayed. The displays may contain instructions (e.g., written, pictorial, or audio) provided in the vicinity of the hat (e.g., removable tag on hat, or placard on display rack) that inform the consumer how to obtain the at least one image (e.g., if image is sold separately), or how to affix the image (e.g., if the image is included with kit). Thus, in certain embodiments, the display is a kit or package comprising the hat, the instructions, and, optionally, the at least one image. In certain embodiments, the display is a store-type display rack comprising the hat, the instructions, and, optionally, the at least one image. In certain embodiments, the at least one image is removable.

In certain embodiments, the display comprises: a hat having a brim, said brim having an upper surface and a lower surface; and at least one detachable image adapted to be affixed to the upper surface or lower surface, and/or instructions for (i) obtaining the at least one detachable image or (ii) affixing the at least one detachable image to the upper surface or lower surface. As noted above, in certain embodiments the upper surface or lower surface comprises primary imagery, wherein the upper surface or lower surface is adapted to receive the at least one detachable image over the primary imagery.

In certain embodiments, the display is a kit or package comprising the hat, and the at least one detachable image and/or the instructions. In certain embodiments, the display is a store-type display rack comprising the hat, and the at least one detachable image and/or the instructions. In certain embodiments, the display is a kit or package comprising the hat, and instructions for obtaining the at least one detachable image. In certain embodiments, the display is a kit or package comprising the hat, the at least one detachable image, and instructions for affixing the at least one detachable image to the lower surface of the brim. In certain embodiments, the display is a store-type display rack comprising the hat and instructions, wherein the hat and instructions are provided in a single kit or package, e.g., the instructions are printed on tagging attached to the hat, or the instructions and hat are included in paper or plastic packaging.

In certain embodiments, the store-type display rack further comprises the at least one detachable image, wherein the at least one detachable image is provided in a separate kit or package, i.e., independent of the packaging provided for the hat and instructions. In certain embodiments, the display is a store-type display rack comprising the hat, the instructions, and the at least one detachable image, wherein the hat, the instructions, and the at least one detachable image are provided in a single kit or package.

In certain embodiments, the instructions comprise instructions for affixing the at least one detachable image to the lower surface of the brim. In certain embodiments, the at least one detachable image is adapted to be affixed to the lower surface of the hat. In certain embodiments, the lower surface comprises a polymeric material.

In certain embodiments is described at least one detachable image adapted to be affixed to the upper surface or lower surface of a brim of a hat. In certain embodiments, it is contemplated that the at least one detachable image can be sold separately from the hat, and thus may be displayed and/or packaged independently. However, it is understood that many hats have brims with unique dimensions, i.e., they have upper surface areas and/or lower surface areas that differ amongst hats. For example, NewEra® baseball hats are known to have numerous styles, including the 5950 version. It is known that the 5950 version hats, in turn, have male, female, and child styles, each of which has a brim with unique surface areas. Similarly, the dimensions of a men's 5950 brim will differ from those of an umpire's 505 brim. Accordingly, in certain embodiments is described a display (e.g., in-store rack or kit/package) comprising the at least one detachable image and an identifier associating the detachable image with a hat and the unique dimensions of its brim, such that the image would fit within the physical dimensions defined by the surface area of the upper or lower surface. As alluded to above, in certain embodiments, the detachable image may match or nearly match the unique dimensions of the brim, such that the detachable image covers 95-100% of the surface area of the upper surface or the lower surface (see, e.g., FIG. 2, wherein image 202 matches the unique dimension of brim 106 and covers nearly 100% of the surface area of lower surface 206). In addition, or in the alternative, the display may further comprise instructions for affixing the at least one detachable image to the upper surface or lower surface of a hat brim.

In certain embodiments, the identifier may comprise writing, pictures, and/or coding that allows customers (or even store employees) to match the detachable image with the appropriate hat. For example, in certain embodiments, the detachable image may be contained in packaging, wherein the image is associated with the appropriate hat by printing the type and style (e.g., Men's 5950) somewhere on the packaging. In another embodiment, the unique dimensions of a hat brim style may be linked with the detachable image through a color or image coding system. For example, in one embodiment, a certain color (e.g., red dot) is printed on the packaging of the image. This color can then be associated with a certain style of hat (e.g., women's 5950) by providing a color/style key, which may be provided directly on the packaging or separately on a display rack.

Also described are methods of preparing a hat. In certain embodiments, the method comprises selecting a hat having a brim, said brim having an upper surface and a lower surface; and affixing at least one image to the brim, wherein the at least one image comprises printed imagery disposed on a substrate. In certain embodiments, the method occurs during the initial manufacturing of the hat.

In certain embodiments, the method occurs after the initial manufacturing of the hat. In certain embodiments, the method comprises: at a server, providing an interactive web-based customization tool to a client through a network, the interactive web-based customization tool configured to allow a user at the client to: (i) display a template associated with a user-selected brim type, wherein the user-selected brim type is selected by the user from a plurality of brim types, the template corresponding to dimensions of the upper surface or lower surface of the brim type selected by the user, and creating a customized brim image on the template based on a user-provided digital (e.g., photographic) image; and (ii) print or manufacture the final customized brim image. In certain embodiments, creating the customized brim image on the template is further based on user-provided image positioning and/or user-provided image sizing. In certain embodiments, the method further comprises affixing the final customized brim image to the upper surface or lower surface of the hat.

In certain embodiments, the manufacture of the customized brim image comprise sublimation. In certain embodiments, the printing of the final customized brim image comprises thermal printing, screen printing, or solvent printing. In certain embodiments, the printing or manufacturing comprises providing the customized brim image on a substrate. In certain embodiments, the substrate comprises a polymeric material. In certain embodiments, the polymeric material comprises a vinyl material. In certain embodiments, the method further comprises cutting the substrate. This may be accomplished using any suitable cutting type, including punching, die-cutting, contour cutting, or liner cutting. The printing and cutting may be accomplished by a single print/cut device, including Roland DGA® print/cut devices such as the SOLJET or VersCAMM.

Methods for preparing, using, and marketing the hats described herein will be apparent to those of ordinary skill in the art, with exemplary procedures being described below.

EXAMPLES Example 1

An image was affixed to the lower surface of the hat similar to the image shown in FIG. 2 by implementing the following process:

-   -   a. Imagery was digitally printed onto sublimation transfer         paper.     -   b. A fabric substrate was loaded onto a station for sublimation         printing.     -   c. The transfer paper was aligned with the substrate and heat         and pressure was applied to the substrate at 350 to 450° F. to         transfer the imagery to the substrate.     -   d. The transfer paper was peeled off the substrate to expose the         transferred imagery and, thus, the final image.     -   e. The image (comprising the imagery disposed on the substrate)         was affixed to the lower surface of a hat brim by detachable         stitching.

Example 2

An image is affixed to the lower surface of the hat similar to the image shown in FIG. 2. The lower surface of the hat comprises a primary image that will be covered by the image prepared according to the following:

-   -   a. Photographic image is provided to an interactive web-based         customization tool over a network.     -   b. A template associated with a particular brim type, based on         the dimensions of the lower surface of the brim type, is         selected from a plurality of brim types.     -   c. Based on the photographic image provided, a customized brim         image is provided on the template.     -   d. The digital rendering of the customized brim type is sent to         a print/cut device, which prints the final customized brim image         on a vinylic substrate having a low-tack backing, and cuts the         substrate to fit the template dimensions. 

1-198. (canceled)
 199. A display comprising: a detachable image adapted to be affixed to the upper surface or lower surface of a brim of a hat, wherein the brim has a unique dimension, and wherein the detachable image is adapted to fit within the unique dimension when affixed to the upper surface or the lower surface; and at least one of (i) an identifier associating the at least one detachable image with the unique dimension, or (ii) instructions for affixing the at least one detachable image to the upper surface or the lower surface.
 200. The display according to claim 199, wherein the at least one detachable image comprises imagery derived from at least one digital image capture.
 201. The display according to claim 199, wherein the at least one image comprises imagery disposed on a substrate.
 202. The display according to claim 201, wherein the imagery comprises printed imagery or sublimed imagery.
 203. The display according to claim 201, wherein the imagery has a resolution of at least 150 dots per inch.
 204. The display according to claim 199, wherein the display comprises the identifier and the instructions.
 205. The display according to claim 199, wherein the at least one identifier comprises at least one of writing, pictures, or coding.
 206. The display according to claim 205, wherein the at least one identifier comprises a smart code, a bar code, or a color code.
 207. The display according to claim 199, further comprising the hat.
 208. The display according to claim 199, wherein the upper surface and the lower surface each have a surface area.
 209. The display according to claim 208, wherein the unique dimension comprises the surface area of the upper surface and/or the surface area of the lower surface.
 210. The display according to claim 209, wherein the detachable image is adapted to fit within the surface area of the upper surface or the lower surface.
 211. The display according to claim 210, wherein the detachable image is adapted to cover about 75% to about 100% of the surface area comprising the upper surface or lower surface.
 212. The display according to claim 210, wherein the at least one detachable image is adapted to cover about 90% to about 100% of the area comprising the upper surface or lower surface.
 213. The display according to claim 199, wherein the display is a kit or package comprising the at least one detachable image, and the identifier and/or the instructions.
 214. The display according to claim 213, wherein the kit or package further comprises the hat.
 215. The display according to claim 199, wherein the display is a store-type display rack comprising the at least one detachable image, and the identifier and/or the instructions.
 216. The display according to claim 215, further comprising the hat.
 217. The display according to claim 199, wherein the display is a store-type display rack comprising the detachable image, and the identifier and/or the instructions, wherein the detachable image, and the indicator and/or instructions, are contained in a single kit or package.
 218. The display according to claim 199, wherein the display is a store-type display rack comprising the detachable image, and the identifier and/or the instructions, wherein the detachable image, and the indicator and/or instructions, are contained in a separate kit or package. 